CENTRIFUGAL PUMPS
HANDBOOK
Fire Pump Systems-
Design and Specification
Think your fire pumps are just like the rest of your fluid-movers? Think again.
Rigorous standards and certifications make sure these life-savers are up to snuff.
by George Lingenfelder and Paul Shank, Precision Powered Products
P
oint of view is everything
when discussing fire pump
systems. For the engineering-
contractor, they are relatively
uncommon systems referencing
specifications unheard of in conven-
tional process units. To the purchas-
er, they are mandated systems that
take time, space and capital away
from money-making units. For
users, fire pump systems are (or
should be) a once a week test
requirement.
But in spite of the time, space and
money constraints, fire pump sys-
tems must work as required. Period.
Hundreds of lives and millions of
dollars in hardware and production
costs rely on the performance of
these systems. Fortunately, they
almost always work.
Because of the critical nature of
this service, one might think that
industry standards could simply be
invoked to insure reliable design
and specification. Of course they
can. They just never are. At least not
without the addition of supplemen-
tal proprietary specifications that
can conflict with industry standards,
government regulations and some-
times with the basic system design.
Seemingly minor requirements can
result in the loss of a listing agency
label and render a perfectly func-
tional system unacceptable to insur-
ers or governmental agencies.
Pumps
The basic fire pump system
includes a UL (Underwriters
Laboratory) or FM (Factory Mutual)
listed pump, driver and controller.
Pumps are rated in discrete incre-
ments starting at 25 gpm and extend-
ing through 5000 gpm. Each capacity
designation is tested for compliance
with NFPA 20 (National Fire
Protection Association) requirements
for performance and by independent
testing institutions such as UL or FM
for design, reliability and safety. A
single pump can be certified for
more than one operating point, but it
must meet all performance and
design criteria at both points.
In the area of basic hydraulic per-
formance, a pump must deliver at
least 65% of rated discharge pres-
sure at 150% of rated flow to
achieve NFPA 20 acceptance. So a
1500 gpm pump rated at 150 psig
must deliver 2250 gpm at a dis-
charge pressure of not less than 97.5
psig. This operating range then
establishes the design parameters
for the piping system and fire fight-
ing equipment. Another require-
ment establishes that the maximum
shut-off head must not exceed 140%
of design head.
Both horizontal and vertical cen-
trifugal pumps are available as list-
ed pumps. (For brevity, we will use
the term "listed" to refer to any
equipment certified by UL, FM, the
Canadian Standards Association
(CSA) or other agency as suitable for
fire pump system application.)
While there are some obvious
design differences between the
requirements for these two styles,
The Pump Handbook Series
Photo 1. Fire water pump with diesel
engine and air start with a nitrogen
back-up system
the performance prerequisites
remain un-changed. It is important
to note that listed pumps are not
designed or manufactured to API
610 standards.
Materials of construction vary
with the type of system and the fire
fighting fluid. The standard cast iron
case with bronze impellers and wear
surfaces is the most common in land-
based applications. This material is
generally suitable for fresh water and
sometimes brackish or even salt
water services, depending on the
length of service and anticipated life
of the unit. Even in fresh water ser-
vices, it is critical to consider casing
corrosion rates when choosing mate-
rials. For more aggressive fluids,
many manufacturers offer various
grades of bronze, including zinc-free
and nickel-aluminum bronze. Higher
alloys of 300 series stainless steel and
Alloy 20 may also be available for
very corrosive services or situations
in which the expected project life is
extremely long.
251

Figure 1. NFPA 20 vertical fire pump sys-
tem with right angle gear, diesel engine
drive and elevated fuel tank with contain-
ment reservoir
Vertical pumps are available in a
much wider range of metallurgies
because of their applications in cor-
rosive offshore environments.
Various grades of bronze are com-
mon, as are higher alloys. Carbon
steel is very rare. Material options
for horizontal units include bronze
casing materials, moving up to car-
bon steel and then austenitic steels
for both case and internals. As with
vertical pumps, higher alloys are
also available for special situations.
From a commercial standpoint,
cast iron-bronze fitted (CIBF) pumps
are the basic choice. Standard alu-
minum bronze materials such as
ASTM B148 Alloy 952 (for vertical
units) generally command price pre-
miums in the 4.5-5 multiplier range.
Nickel-aluminum bronze (B148 Alloy
955) will increase this pricing by an
additional 10-15%. Carbon steel (for
horizontal units) will raise standard
CIBF costs by 3-4 times. Stainless
steel, typically 316SS, increases base
costs by a factor of 5-8 depending
on size. Higher alloys can increase
CIBF costs by up to 8 times.
Auxiliary equipment and acces-
sories offer many possible options
for the pump. While these will be
discussed in greater detail later, it is
important to note that most fire
water pump manufacturers only
252
Figure 2. Plan view of horizontal fire water pump system with diesel
engine drive, discharge piping main relief valve and discharge cone
offer a limited num-
ber of materials and
options for listed
pumps. Pumps (like
drivers and other
equipment) can be
listed for fire pump
service only when
they are manufac-
tured in the same
materials and config-
uration as the design tested by the
certifying agency. Changes in casing
materials, even when poured by the
same foundry using the same pat-
terns, can prevent a manufacturer
from labeling the pump. Likewise,
changing accessories, especially on
engines, can result in the loss of the
label.
In practice, this is usually a
semantic issue and rarely becomes a
significant problem, provided that
the original design or unit was
labeled and that the changes are
clearly upgrades in materials, con-
trol and/or reliability. The impor-
tance of labeling also varies with
the location and type of fire pump
service, as well as responsible gov-
ernment agencies and insurance car-
riers. Most manufacturers offer
labeled equipment in the most ele-
mental fashion for application in the
widest range of markets. This makes
it possible for the specifying engi-
neer and user to work together with
the supplier to develop the best sys-
tem for their application. Even
The Pump Handbook Series
though the end user might cus-
tomize the system and add acces-
sories that void the label, the origi-
nal equipment was labeled, and this
shows the intent of the user to
install labeled equipment.
Drivers
While the pump is the mechani-
cal heart of a fire water system, the
driver is a critical component, fre-
quently requiring more attention in
specification and design. Diesel
engines power the vast majority of
fire water pumps, creating another
difficulty for the specifying engineer.
Most of us have limited experience
with this category of equipment.
They are rare in general plant design
and frequently used only because
the power required exceeds the
available UPS (Uninterruptible
Power Source). Unlike the situation
with motors, the specification and
selection of diesel engines cannot be
foisted off on another discipline.
The basic, listed fire pump
engine, offered by many manufac-
turers, is more than adequate in
terms of reliability and service life.
After all, this system will only oper-
ate once a week for thirty minutes
until it is called on to run in a real
emergency. Then it will operate for
eight hours (the standard fuel tank
sizing) or until it is destroyed in the
conflagration.
A great deal of time and energy is
expended on the starting system,

Photo 2. Custom fire water pump sys-
tem designed for Class 1, Groups C &
D and Division II. The controller fea-
tures all NEMA 7 switches mounted in
a stainless steel cabinet. The battery
charger and battery case are purged
and constructed of 316SS. The sys-
tem has a primary electric start with a
back-up hydraulic system.
Photo 3. Vertical fire water pump for
offshore installation. Compressed air
start with back-up nitrogen system
and expansion receiver
which often includes back-up start
systems and sometimes even multi-
ple starting systems. Basic systems
include dual sets of batteries. Also
commonly available are pneumatic
systems—compressed air with bot-
tled nitrogen back-up and hydraulic
starting systems. Many of the larger
engines, above 200 hp, offer two
ports for starters, so that two types
of starting systems can be used.
This having been said, most experi-
enced engine users agree that if the
unit does not start within the first
three to five seconds, the likelihood
of starting at all is just about nil. For
this reason, it is very important to
pay close attention to the starting
cycle of the unit during the weekly
exercise sessions. Remedy any diffi-
culties or malfunctions at once.
Although relatively uncommon,
some systems also use motors, espe-
cially when the firewater pumps are
also used for water lift or wash-
down services. Whether they are
more reliable remains an open dis-
cussion. The simple fact of their
predominance as drivers has made
them more acceptable. Like other
major components of fire pump sys-
tems, motors are available in
UL/FM and CSA listed varieties
from a wide range of manufactur-
ers. While still not widely accepted,
the most recent revision of NFPA 20
(January 1998) now requires fire
pump motors to be UL listed.
Controllers
Controllers were the last major
component of fire pump systems to
receive certification by various list-
ing agencies. Unlike other compo-
nents, however, they come with a
wide range of options and even pro-
vide remote system contacts for the
other pump, driver and other
options that may need to be incor-
porated into the control scheme.
A few areas in the design and
specification of the controller
should be reviewed carefully. The
first is area classification. Unusual
as it may seem to designers and
specifiers who are unaccustomed to
it, standard drivers and controllers
are not rated for any National
Electrical Code (NEC) area classifi-
cation. Depending on the manufac-
turer, they can add this as an option
or build a custom controller that
meets a specific area’s classification.
Meeting a Division I or II classifica-
tion usually involves adding a Z-
purge system, which can be expen-
sive relative to the cost of the con-
troller (typically increasing cost by
up to 50%), but this is currently the
most cost-effective method to meet
these requirements. Custom con-
trollers, a very expensive alterna-
tive, will generally incorporate her-
metically sealed or NEMA 7 enclo-
sures for all potentially arcing
devices. In addition, diesel engine
control sensors and battery start
systems are not intended for a clas-
sified area. Electric motors must
also be specified for the area.
Pneumatic engine controllers with
The Pump Handbook Series
air start systems are an obvious
alternative when area classification
becomes an issue. Although not com-
mercially available as UL/FM listed
units, it is generally agreed that they
are inherently explosion-proof
because they have no electrical com-
ponents. Custom built electric con-
trollers, however, can meet the area
classification requirements of any
facility. Controllers incorporating
PLC logic are also available as stan-
dard commercially available, but not
as UL/FM listed units, or pneumatic
controls as custom built units.
Custom manufactured controllers
are becoming more common, espe-
cially in the HPI/CPI markets to
meet NEC area classifications. It is
important to note, however, that
while these units may consist
entirely of UL (or other) listed com-
ponents, this does not convey a UL
listing to the controller. Thus, the
controller does not meet the UL218
requirements. This may appear to
be a subtle differentiation, but local
codes and regulations, as well as
insurance requirements, may req-
uire sacrificing an area classification
for a UL/FM listing.
Instrumentation
Fire pump systems are not
process systems. Thus, much of the
advanced instrumentation applied to
process systems is relatively uncom-
mon in the world of fire pumping.
However, some systems include
transmitters and other “smart”
devices that provide additional infor-
mation to the user. Carefully review
the purpose and function of these
devices to determine their value
under the anticipated operating con-
ditions and to insure that they pro-
vide valuable information without
contributing to needless complica-
tion. Unlike a process system,
where almost every eventuality can
be understood, evaluated and pre-
pared for, the full array of condi-
tions under which a fire pump sys-
tem will be used is almost impossi-
ble to imagine. Controls should be
as simple and straightforward as
possible, lest they fall victim to the
law of unintended consequences.
253

Photo 4. A 570 hp V-12 diesel engine driver
for all nickel aluminum bronze fire water
pump producing 3500 gpm at 180 psi.
Industry Standards
Two major organizations are the
primary promulgators of standards
for fire pump systems, and their
roles, far from being conflicting, are
complementary.
National Fire Protection
Association
The National Fire Protection
Association, through its NFPA 20
Standard for the Installation of
Centrifugal Fire Pumps, provides
the most complete set of provisions
for the design and installation of
various components as well as the
overall system. The NFPA 20 sets
standards for design and construc-
tion of all the major components in
the fire pump system, including
minimum pipe sizing tables, elec-
tric motor characteristics, perfor-
mance testing, and periodic testing
and system design. NFPA 20 fur-
ther attempts to develop a safety
standard or level of performance
for centrifugal fire pump systems
to provide a reasonable degree of
protection for life and property.
Under these provisions, alternate
arrangements and new technolo-
gies are permitted—and in fact
encouraged.
The National Fire Protection
Association does not, however, certi-
fy or evaluate compliance with its
various specifications and guide-
lines.
NFPA 20, while the source of
some performance requirements, is
best known for its detailed design
provisions for all components com-
monly found in fire pump systems.
254
Unlike many industry standards
Underwriters Laboratories
that address only the design, manu-
Underwriters Laboratories (UL)
facture and testing of specific com-
reviews equipment and systems
ponents, NFPA 20 is a veritable
from a performance orientation.
'how-to' manual for the engineer or
The organization provides an inde-
user who needs to develop guide-
pendent, third party evaluation of
lines and specifications for fire
manufacturers for a variety of com-
water systems. Taken as a complete
ponents, but for fire pump systems
document with referenced texts,
the primary specifications for our
this standard alone will assure the
consideration are UL448 for pumps,
purchase and installation of a reli-
UL1247 for diesel engines and
able fire pump system. Take care in
UL218 for controllers.
developing additional specifications,
In certifying equipment to these
whether stand-alone or ancillary, to
standards, UL reviews construction
avoid conflicts with NFPA 20.
design, materials of construction
Because of the detailed nature of
and overall performance. These
this specification, add-on require-
reviews assess the ability of the
ments can frequently have the effect
equipment to perform the task for
of actually diminishing the stan-
which it is to be rated. Following
dards.
initial certification, UL maintains an
Here again it is important to keep
ongoing surveillance program to
in mind the function of the equip-
insure continued adherence to
ment in a fire pump system.
design and performance criteria. UL
Contrary to the design considera-
field representatives make unan-
tions in process units, fire pump
nounced visits to all manufacturers
systems should be designed to oper-
displaying the UL label. If team
ate reliably under the most adverse
members encounter problems or
conditions for as long as required,
questions, they may schedule more
but typically this is only a matter of
frequent visits.
hours. In a process unit, systems are
UL standards are among the most
designed to protect themselves with
stringent in the industry, and equip-
various shutdowns and monitors.
ment certification is necessarily
Fire pump systems are designed to
very specific. So what happens
protect the plant and personnel
when a listed product is modified to
even if that means operating to
meet customer specifications or site
destruction. In other words, three
specific requirements? If the change
hours into a fire fighting event, the
is clearly an upgrade to the existing
vibration level of the diesel engine
listed design and not a major
driver is of no significance so long as
change in the product, UL will fre-
the pump continues to deliver ade-
quently certify the modification
quate flow.
without re-testing. Major modifica-
NFPA 20 includes pump design
tions, of course, must go through
guidelines for vertical shaft turbine
the complete certification process.
pumps, horizontal (both end-suction
The manufacturer is responsible for
and split-case) and vertical in-line
initiating changes to the listing.
pumps. It also includes standards
UL448 sets the standards for cer-
for motors, both horizontal and ver-
tification of centrifugal pumps for
tical, right angle gears and diesel
use in fire water systems. As previ-
engine drives.
ously noted, UL448 is based on the
Additionally, the guidelines are
ability of the unit to perform under
an excellent resource for auxiliary
the conditions of service required
and ancillary equipment found in
and according to the manufacturer's
most fire water pump systems. For
specifications with regard to total
example, the diesel engine specifica-
differential head (TDH), capacity,
tions include not only requirements
and efficiency or power require-
for the engine itself, but also the
ment. Materials of construction are
fuel supply, exhaust system and
reviewed for strength and corrosion
control system operation.
resistance. Each unit or size to be
The Pump Handbook Series
certified is given an operational per-
formance test and is also hydrotest-
ed to twice the manufacturer's pub-
lished Maximum Allowable
Working Pressure. This is a substan-
tial increase over pump industry stan-
dards of 150% hydrotest pressures.
After certification, UL448 req-
uires that each unit bearing the UL
mark be tested successfully for
hydrostatic integrity and hydraulic
performance.
Diesel engines fall under the
scrutiny of UL1247. Again, the
emphasis is on performance.
Certification requirements include
extended testing on dynamometers
as well as speed control. Because of
the importance of driver speed in
centrifugal pump applications,
speed control and overspeed shut-
down operation are critical areas.
Units are also tested for their ability
to start under a wide range of condi-
tions, both hot and cold.
After certification, each produc-
tion unit shipped must be subjected
to a dynamometer test including
performance checks of the speed
control and overspeed shutdown
systems.
Engine and motor controller spec-
ifications are covered by UL218,
which is written and administered
by the Industrial Controls section of
Underwriters Laboratories. While
this section is closely aligned with
UL's primary purpose to review
equipment for fire and shock haz-
ards, the critical nature of fire pump
controllers makes performance an
important concern of this standard.
These units are reviewed for safety,
of course, but the importance of
starting a fire water pump under
emergency conditions warrants a
different philosophy in certifying
the controllers.
Controllers are inspected with
special attention to their ability to
signal—that is, to notify remote per-
sonnel of any abnormal conditions
in the controller system—as well as
to be able to accept remote instruc-
tions for starting. Diesel engine con-
trollers, besides providing a starting
signal to the engine, must also pro-
vide charging current for the batter-
ies, perform a weekly starting and
run test of the engine and driven
equipment train, as well as provide
visual and audible indication of var-
ious engine failures. These include
failure of the engine to start, shut-
down from overspeed, battery fail-
ure, battery charge failure and other
abnormal conditions. Diesel engine
controllers also include pressure
recorders to sense pressure in the
fire protection system and confirm
unit performance on demand or
during weekly tests.
Electric motor control require-
ments also focus on the ability of
the unit to start the motor drive.
This overriding concern is demon-
strated in unit design, for fire sys-
tem controllers are different from
standard motor controllers. This is
perhaps best demonstrated by their
use of either a listed fire pump cir-
cuit breaker or a non-thermal
instantaneous trip circuit breaker
with a separate motor overcurrent
protective device for protection
against overcurrents and short cir-
cuits. Another difference between
these and standard controllers is
that once a fire pump controller is
under emergency conditions, it is
prevented from shutdown except
when it is under a condition more
threatening than the fire or until
conditions return to normal standby.
Surprisingly, UL lists no fire pump
controllers for installation in haz-
ardous (classified) locations. To meet
Division I or II requirements, con-
trollers must be custom designed
with a suitable hazardous location
protection method. They must either
have a purge system or be explosion
proof. Custom designs, of course,
will incorporate either NEMA 7 com-
ponents or enclose elements in explo-
sion-proof boxes. The X and Z-purge
systems are the most common.
For international installations, the
problems are compounded because
no harmonized IEC (International
Electrotechnical Commission) stan-
dards exist that address fire pump
controllers This situation, however,
is being addressed by a joint working
committee of the NFPA and UL that
is developing an IEC standard that
The Pump Handbook Series
will incorporate NFPA 20 and UL218
requirements. At present, the com-
mittee has developed a draft specifi-
cation and submitted it to the IEC
for inclusion as a new work item
proposal (NWIP). Following accep-
tance as a NWIP, the IEC will con-
vene a group to review and comment
on the standard for development as
an IEC publication. Given the impor-
tance of international markets, this
move will be an appreciated step for
U.S. based manufacturers.
Conclusion
Fire pump systems are designed
to protect life and property. In this
area, specifiers, owners and opera-
tors need to change their perspective
on equipment, controls and opera-
tion. Performance and reliability
must be the priority in design, pur-
chase and maintenance. While site
specifications and purchaser require-
ments certainly must be considered,
simpler is usually better. The ability
of the system to perform reliably
under the most severe conditions, for
the protection of life and property,
must be the driving consideration. n
Special thanks to Kerry Bell and
Dave Styrcula at Underwriters
Laboratories for their assistance.
George Lingenfelder is a principal
and founder of Precision Powered
Products, a systems design and fabrica-
tion firm serving the oil and gas indus-
try the petrochemical/refining markets.
He worked for major engineering and
construction companies as a Systems
Engineer for ten years before starting
Precision Powered Products in 1984.
Mr. Lingenfelder received his B.S.
degree in mechanical engineering from
the University of Houston
Paul Shank is with Precision
Powered Products in Houston, Texas.
He has more than 20 years of sales
and engineering experience in the spe-
cialty process equipment field. He has
authored technical articles and co-
authored several software programs
for the selection and pricing of pumps,
compressors and steam turbines. Mr.
Shank received a B.S. degree from the
University of Houston.
255